Jiang Jiang, Ze-Jiu Ye, Guang-Chao Han, Fu-Chu Liu, Yan Wan, Wei Xiong, Wei Bai, Liang Hao
{"title":"Multi-objective optimization of forming quality for horizontal circular internal flow channels fabricated using laser powder bed fusion","authors":"Jiang Jiang, Ze-Jiu Ye, Guang-Chao Han, Fu-Chu Liu, Yan Wan, Wei Xiong, Wei Bai, Liang Hao","doi":"10.1007/s40436-026-00623-x","DOIUrl":"10.1007/s40436-026-00623-x","url":null,"abstract":"<div><p>In laser powder bed fusion (LPBF), circular internal flow channels in small aerospace satellite integration plates must be fabricated without supporting structures, particularly for horizontal channels. This can cause melt-pool collapse defects during the LPBF process, leading to reduced relative density, increased surface roughness, and thermal stress-induced deformation. To address these challenges, we developed a multi-objective collaborative optimization forming method for fabricating <i>φ</i>1-mm TC4 horizontal circular internal flow channels via LPBF. Optimal heat treatment parameters were obtained to enhance the corrosion resistance of the internal flow channels. The results revealed that the forming quality of the horizontal circular internal flow channels was comprehensively improved. The channel achieved a relative density of 99.64%, lower and upper surface roughness of 17.4 μm and 13.5 μm, and <i>x</i> and <i>z</i> dimensional errors of 4.12 μm and 3.47 μm, respectively. The best corrosion resistance was obtained at an annealing temperature of 950 °C and a holding time of 3 h, resulting in <i>α</i> and <i>β</i> phase contents of 96.5% and 3.5%, respectively.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"954 - 972"},"PeriodicalIF":3.9,"publicationDate":"2026-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309794","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Strain transfer mechanism and axial/radial force sensing technology for flexible shape sensors","authors":"Meng-Xuan Wang, Ying-Jie Yu, Xiang-Yan Chen, Jin-Wu Qian","doi":"10.1007/s40436-025-00588-3","DOIUrl":"10.1007/s40436-025-00588-3","url":null,"abstract":"<div><p> Shape reconstruction and force measurement of surgical diagnostic tools are crucial to ensure surgical safety. This study focuses on the strain transfer of an overall flexible fiber Bragg grating (FBG) shape sensor. A theoretical equation of strain transfer was established, with the fiber and bonding layers as the core structures. The response characteristics of the fibers under axial and radial forces were investigated. Through finite element simulations, the strain values of the bonding and fiber layers were analyzed and compared with the theoretical values to determine the influence of the bonding layer thickness, elastic modulus, encapsulation length, and Poisson’s ratio on the strain transfer. A 260-mm-long, 2-mm-diameter, substrate-free FBG shape sensor was encapsulated, and axial/radial force sensing experiments were conducted to verify the theoretical force-wavelength change model. Additionally, shape reconstruction experiments were performed on a flat surface, achieving a 3.68% shape reconstruction accuracy. In surgical diagnosis and treatment, this research enables doctors to monitor the in vivo status of surgical tools and their interactions with tissues in real time, thereby preventing tissue damage, enhancing surgical safety and precision, and laying a theoretical foundation for the quantitative analysis of nociceptive perception in medical endoscopic diagnosis and treatment.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"1045 - 1063"},"PeriodicalIF":3.9,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309856","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Qiao-Zhen Su, Hong Sun, Jun Ma, Meng-Meng Liu, Xuan-Cheng Hao, Yu-Li Liu, Heng Li
{"title":"Effect of mandrel on forming quality in sizing process of double-wall brazed tube","authors":"Qiao-Zhen Su, Hong Sun, Jun Ma, Meng-Meng Liu, Xuan-Cheng Hao, Yu-Li Liu, Heng Li","doi":"10.1007/s40436-026-00600-4","DOIUrl":"10.1007/s40436-026-00600-4","url":null,"abstract":"<div><p>The sizing process is a critical intermediate forming procedure in multipass rolling-brazing for producing double-wall brazed tubes (DWBTs). In the sizing process, the mandrel plays an essential role in accurately forming DWBTs and ensuring tight fitting of the inner and outer layers, which is of great importance for the success of the subsequent brazing operation, as well as the quality of the final product. However, achieving control over precise dimensions and uniform stress distribution in the formed tube remains a challenge. This study aims to obtain the optimal design parameters of an olive-shaped mandrel by investigating the effect of its key parameters, specifically the length and diameter of the mandrel head, on the forming quality of DWBTs during the sizing process. The results of experimental and numerical studies show that, with the increasing length and diameter of the mandrel head, the cross-section of the formed double-wall tube gets closer to an ideal roundness. An increase in the mandrel head length results in a more uniform stress distribution but a decreased uniformity in the wall thickness. In contrast, an increase in the mandrel head diameter improves the geometrical accuracy of the formed double-walled tube; however, the uniformity of the stress distribution decreases owing to the higher sizing force. Through a comprehensive analysis of multiple forming indices such as roundness, wall thickness distribution, and stress distribution, the optimal design parameters of the sizing mandrel are determined, offering practical guidance for achieving high-quality DWBT manufacturing.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"1013 - 1026"},"PeriodicalIF":3.9,"publicationDate":"2026-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309526","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Influence of thermal effects and fluid dynamics on part sedimentation in volumetric additive manufacturing","authors":"Yi-Fei Wang, Xiao-Xiao Han, Xiao-Long Zhu, Wei Zhu, Feng Chen","doi":"10.1007/s40436-026-00599-8","DOIUrl":"10.1007/s40436-026-00599-8","url":null,"abstract":"<div><p>Part sedimentation in volumetric additive manufacturing (VAM) technology is a well-known detrimental effect that can significantly deteriorate printing resolution and shape fidelity. This study reveals the underlying mechanism by which process parameters and material properties affect the sedimentation properties of parts fabricated by VAM, considering the intrinsic thermal process and its interaction with polymerization kinetics. It was found that thermally induced changes in material viscosity and polymerization parameters played an essential role in regulating sedimentation behavior. Lowering the ambient and initial printing temperatures can increase viscosity resistance and thus weaken the sedimentation phenomenon, whereas a longer printing time adversely influences part sinking. Optimal thermal conditions that simultaneously ensure low sedimentation and a relatively short printing time should be determined during printing, particularly for thermally thinned materials. Importantly, using the wall-end effect, the model revealed that settlement could be effectively mitigated by solidifying the part near the bottom of the container. The experiments confirmed a reduction of approximately 39.4% in sedimentation displacement. The thermal-solid-fluid coupled model developed in this study offers a valuable tool to guide the design of new photosensitive materials as well as the optimization of process parameters, which is essential to improve the printing outcomes of VAM and thus facilitate its broader applications.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"991 - 1012"},"PeriodicalIF":3.9,"publicationDate":"2026-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310029","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
C. Tosto, L. Saitta, R. Barbagallo, G. Mirone, I. Blanco, G. Cicala
{"title":"Correlation between ultimate tensile strength and thermal conductivity of 316L metal parts obtained through fused filament fabrication","authors":"C. Tosto, L. Saitta, R. Barbagallo, G. Mirone, I. Blanco, G. Cicala","doi":"10.1007/s40436-026-00594-z","DOIUrl":"10.1007/s40436-026-00594-z","url":null,"abstract":"<div><p>This study investigates the mechanical properties and thermal conductivity of metal parts produced using metal fused filament fabrication (Metal FFF), focusing on three distinct printing profiles (Fast, Strong, and Quality) provided by the material manufacturer. The correlation between thermal conductivity and mechanical strength is explored, aiming to optimize part performance by understanding the impact of printing parameters. Results demonstrate that the “Quality” profile delivers superior mechanical strength and thermal conductivity due to enhanced inter-layer bonding and reduced porosity, as confirmed by SEM analysis. Conversely, the “Fast” profile offers the lowest performance but maximizes productivity and cost-efficiency. The “Strong” profile represents a balanced compromise among mechanical performance, thermal properties, and manufacturing cost. This work highlights the potential of using thermal conductivity tests as a faster and more resource-efficient proxy for mechanical testing in initial assessments. Such tests are particularly valuable in applications where thermal conductivity is a critical requirement (e.g., battery thermal management systems, heat exchangers, cooling systems in electronic, etc.). Future research should focus on developing predictive models to further streamline the characterization and optimization of Metal FFF processes for industrial applications.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"973 - 990"},"PeriodicalIF":3.9,"publicationDate":"2026-03-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-026-00594-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310728","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Development of a bio-inspired manufacturing framework for piezoelectric sensors","authors":"Chang Ge, Yi-Pan Zuo","doi":"10.1007/s40436-026-00598-9","DOIUrl":"10.1007/s40436-026-00598-9","url":null,"abstract":"<div><p>This study proposes and experimentally validates a bio-inspired manufacturing strategy for piezoelectric sensors that emulates the modular and decoupled formation mechanisms observed during insect metamorphosis. This process enables independent fabrication and optimization of the mechanical structure, piezoelectric element, and electrode interconnects, followed by low-temperature heterogeneous integration through heat-activated bonding, thereby overcoming persistent challenges in the conventional fabrication processes of piezoelectric sensors. A series of characterizations confirmed that the laser micromachining of polyvinylidene difluoride (PVDF) and polyimide (PI)-Cu films maintained material integrity, while adhesive bonding achieved uniform, defect-free interfaces. Proof-of-concept piezoelectric accelerometers fabricated via the proposed process exhibited a mean sensitivity of 3.17 pC/g, 5% bandwidth of 350 Hz, and intersample deviation below 5%, matching the performance of devices fabricated using classical microelectromechanical system (MEMS) techniques. Furthermore, wearable tests demonstrated the ability of the sensors to detect subcutaneous vocal-fold vibrations and distinguish between different spoken words, verifying their functional stability and application feasibility. The results establish a generalizable and low-temperature polymer-based manufacturing framework for creating complex, highly reliable piezoelectric sensors with direct implications for the future development of multimodal, flexible, and bio-integrated sensing systems.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"937 - 953"},"PeriodicalIF":3.9,"publicationDate":"2026-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310691","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Xing-Xing Li, Jun-Sheng Wang, Xing-Hai Yang, Cheng-Peng Xue, Yi-Sheng Miao, Quan Li, Qing-Huai Hou, Zhong-Yao Li, Xue-Long Wu, Shi-Hao Wang
{"title":"In-situ observation of hydrogen micropore evolution during directional solidification of Al-Cu-Li alloy","authors":"Xing-Xing Li, Jun-Sheng Wang, Xing-Hai Yang, Cheng-Peng Xue, Yi-Sheng Miao, Quan Li, Qing-Huai Hou, Zhong-Yao Li, Xue-Long Wu, Shi-Hao Wang","doi":"10.1007/s40436-026-00597-w","DOIUrl":"10.1007/s40436-026-00597-w","url":null,"abstract":"<div><p>This study used X-ray microtomography to conduct in-situ observations of hydrogen micropore nucleation and growth during the directional solidification of an Al-Cu-Li alloy in a vacuum temperature gradient furnace. The kinetics of hydrogen microporosity evolution were traced and elucidated, and the micropore migration mechanism during directional solidification was revealed. The observed evolution of hydrogen microporosity can be divided into two basic stages: the first stage was characterized by micropore nucleation manifested as a sharp increase in the number density of micropores, with an average micropore nucleation temperature of (607 ± 9.6) °C and the maximum formation rate of 1.6 micropores/s; the second stage (560–595 °C) was dominated by micropore growth, as indicated by a significant increase in equivalent diameter at the maximum growth rate of 4.05 μm/s. The micropore growth kinetics were effectively described by an exponential function based on these observations. Notably, the Marangoni flow field induced by the differences in surface tension around the hydrogen micropores in the mushy zone caused them to migrate towards the cooler side of the temperature gradient, in contrast to the commonly observed migration of micropores towards the warmer side of directionally cooled metals; this atypical phenomenon was caused by the different effects of temperature and alloy component concentrations (Cu and Li elements) on surface tension. The cryophilic migration behavior observed in this study was primarily influenced by the Cu concentration, i.e., the Mukai-Lin-Laplace effect.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"882 - 899"},"PeriodicalIF":3.9,"publicationDate":"2026-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310200","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Impacts of vehicle electrification on Al-Si castings: an overview of current manufacturing processes, mechanical properties, and applications","authors":"Nagasivamuni Balasubramani, Mohamed El Mansori","doi":"10.1007/s40436-025-00590-9","DOIUrl":"10.1007/s40436-025-00590-9","url":null,"abstract":"<div><p>The transition from internal combustion engines (ICEs) to battery or fuel-cell electric vehicles (EVs) directly impacts the metal casting industry, presenting both opportunities and challenges. Traditional manufacturing processes in foundries have primarily focused on ICE vehicles for decades, while the shift to EV impacts existing infrastructure necessitating new requirements and investments. The demand for lightweight materials in EVs continues to increase, outpacing the requirements of current ICE vehicles. Cast Al alloys play an indispensable role in automotive light weighing, offering an attractive combination of properties including strength and ductility, corrosion resistance and castability. Despite predictions regarding market share, and growth of Al in EVs, relatively few studies have analysed the impacts of casting alloys, manufacturing processes and alloy distribution in EV applications. Therefore, this overview aims to explore the effects of EVs on cast components by focusing on the changes to drive systems and the parts lost or gained due to this transition. The methodologies and manufacturing process are reviewed for design and simulation, microstructure refinement, and mechanical properties. More emphasis is provided on advanced/hybrid methods (mega castings, rheo- and compound casting) and functional designs utilizing metal and sand 3D printing processes. Most research findings indicate the lightweighting, along with structural and functional integration will drive the casting applications for EVs. Secondly, castings for EVs create a surging demand for primary alloys and significantly reduce the market share of secondary alloys in the future. Potential avenues for future research on alloy development, process variables and upgradation, and recyclability issues are highlighted.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"900 - 936"},"PeriodicalIF":3.9,"publicationDate":"2026-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-025-00590-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310424","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Arash Seifoddini, Arefeh Azad, Mohammad Hossein Mosallanejad, Abdollah Saboori
{"title":"Multi-objective process parameter optimization using a hybrid reinforcement/machine learning model in metal additive manufacturing","authors":"Arash Seifoddini, Arefeh Azad, Mohammad Hossein Mosallanejad, Abdollah Saboori","doi":"10.1007/s40436-026-00596-x","DOIUrl":"10.1007/s40436-026-00596-x","url":null,"abstract":"<div><p>Additive manufacturing enables the production of complex geometries and lightweight structures. However, producing defect-free components fundamentally depends on the careful optimization of process parameters that influence critical factors, such as melt pool depth, in laser powder bed fusion (L-PBF), an important class of metal additive manufacturing methods. Hence, for the first time, this paper presents a novel data-driven framework that integrates machine learning (ML) with reinforcement learning (RL) to optimize process parameters, ensuring the desired melt pool characteristics while meeting multi-objective design criteria. Experimental data from the literature were extracted to train several ML models, with Gaussian process regression (GPR) featuring a Matérn kernel proved to be the most accurate predictor. This model served as the digital twin of the L-PBF process and was integrated with a <i>Q</i>-learning-based RL agent to derive the optimal process parameters. The GPR model achieved a high prediction accuracy (root mean squared error (RMSE): 34 µm, the coefficient of determination <i>R</i><sup>2</sup>: 96.05%) for L-PBF Ti6Al4V alloy using minimal training data. Integrating a <i>Q</i>-learning framework with ML demonstrated superior performance in deriving process parameters that achieved the target melt pool depth while minimizing the normalized enthalpy, directly impacting the formation of the keyhole defect.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 4","pages":"829 - 849"},"PeriodicalIF":3.9,"publicationDate":"2026-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-026-00596-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310130","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}